Rachel LevineME (Lead Engineer)
Sam PerryME
Amy RyanISE (Lead Programmer)
Kwadwo Opong MensahEE
P13552 Projected Image Prototyping System
Faculty Guide John Kaemmerlen Primary Customer Denis Cormier
Michael DiRomaISE (PM)
The primary objective of this project is to create a projected image 3D printer with the ability to produce a three-dimensional part.
Project Description
Customer Needs
SpecificationBuild a 3D PartBuilt with
PhotopolymerLayer ThicknessFeature Resolution
Part Size DimensionSoftware to control
all aspects
YesYes25 – 250 MicronsAble to report
process capabilitiesMax Size of 3” by 4”Fully Automated
Engineering SpecificationsTarget Value
Photopolymer: Light sensitive resin that cures when light hits it
A black and white image or “slice” is a way to selectively cure the resin
Concept Summary
Black and white image
from DLP projector
System Architecture
Physical Setup
Bath glass is covered with TeflonBath glass is secured between top and bottom
bath assemblyBath assembly is attached to the platform Bath filled with resinBuild Platform lowered Completely
Platform is lowered using the jog buttons
System Architecture
Inputs to LabViewSTL fileUnits (millimeters and inches)Slice Thickness – 50 Microns (ideal conditions)Base Speed – 1600 (ideal conditions)Cure Time – 3 seconds (ideal conditions)
System Architecture
Windows Command Line and Slicer
Information Gathered3D Object size (length, width, and height)
Functions Performed Object sliced Images background changed to black and core
changed to white Images saved to desktop
System Architecture
LabView, the projector, and the Microcontroller
Steps to move determined by layer thickness
Build Platform moves up to far enough to separate from the Teflon then down to the appropriate distance
The image will project for the set cure time then it will display a black screen.
System Architecture
Stepper Motor
Lead Screw, Linear Guide
Sandblasted Aluminum Build Platform
Jog Buttons
Resin Bath and Teflon Film
DLP Projector
Motion Controller
Motion Assembly
Macro Lens Optics
Sandblasted Aluminum Build PlatformIncreased adhesion
Teflon FilmDecreased adhesion
Lead ScrewAnti-backlash nut12.7μm (0.0005”) resolution per step
Linear GuideHigh loading support with low deflection
Motion ControllerIntegration with software
Features
System Testing Results
SuccessesMultiple complete
parts produced
System fully automated
Utilizing past teams materials (projector, case, formula, etc)
Inconsistent adhesion to build platform
Unable to use different photopolymers
Resolution of parts is low
Project Evaluation Failures
Improve Teflon FilmPermanent glass coating
Hard limit switchesDedicated softwareEncoder supportTest different photopolymer resin formulasClean up LabView Programing CodeContinue Detailed testing to determine
optimal settings
Recommendations
All risks can not be accounted forUnidentified risks, external to the project
Overlooked sources of help“Secret formula” found on past teams poster in
week 8 of the second quarter
Better testing structure earlier in the quarterManipulate one variable at a time in a
controlled manor
Lessons Learned
Any Questions?